Course Description

This Workshop will assist in the execution of Process FMEAs using the AIAG & VDA FMEA Handbook. After attending this course, you gain the ability to describe the benefits of a robust technical risk analysis using the PFMEA development approach described in the AIAG & VDA FMEA Handbook, execute a PFMEA applying the 7-Step approach, evaluate the consistency in PFMEA application, measure the effectiveness and efficiency of PFMEA within your organization with linkage to the Cost of Poor Quality (CoPQ), and develop an Implementation Plan for your organization to adopt the AIAG & VDA FMEA. This course also provides insight and hands-on experience with how to develop and implement Control Plans for your manufacturing processes. 

Training In Context: 

The growing phenomenon of automotive OEMs adopting global platforms with similar subsystems, components, and materials is addressed within the automotive supply chain by the development of product family processes (processes that can produce several part numbers to several customers using common manufacturing processes and shared resources). When a manufacturing quality problem occurs in any “product family process” it brings about the potential risk for shipment of defective parts not only for one, but for several customer products, making technical risk mitigation related to manufacturing quality crucial for automotive industry. This challenge cannot be addressed without a robust methodology that takes into consideration all potential failure modes to all potential applications. 

  

The new AIAG & VDA FMEA Handbook is a critical update for the industry that addresses this, and other challenges the automotive industry is facing. The concept of robustness exists throughout all sections of the new PFMEA development approach, which is presented in the new AIAG & VDA Handbook. The Handbook contains a structured method for identifying process steps functions, requirements, and potential failure modes. 

Course Details

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Learning Objectives

• Describe the benefits of a robust technical risk analysis using the PFMEA development approach described in the AIAG & VDA FMEA Handbook. 
• Apply the 7-Steps approach in the execution of an actual PFMEA 
• Evaluate the consistency of PFMEA application cases 
• Measure PFMEA effectiveness, efficiency, and linkage to the Cost of Poor Quality (COPQ) 
• Develop an Implementation Plan for the AIAG & VDA FMEA 
• Describe the type of information that should be entered in each Control Plan column 
• Utilize information gathered from performing an FMEA to construct a Control Plan 
• Evaluate the consistency of Control Plan application cases 
• Develop Control Plans for your manufacturing processes

Who Should Attend

Recommended for Core Process FMEA Team members, including: process/manufacturing engineers, ergonomic engineers, process validation engineers, quality/reliability engineers, project managers, FMEA moderators/facilitators, auditors, and other roles with a limited working knowledge and background with AIAG Process FMEA. 

Agenda

Day 1 

• Overview of FMEA Foundations based on the new AIAG & VDA FMEA Handbook. 
• Applying 7-Steps approach - an instrumental, integrated with lessons learned, and error-proofing driven method to develop FMEAs 
• PFMEA 1st Step – Planning and Preparation. 
• PFMEA 2nd Step – Structure Analysis 
• PFMEA 3rd Step – Function Analysis 

Day 2 

• PFMEA 4th Step – Failure Analysis 
• PFMEA 5th Step – Risk Analysis 
• PFMEA 6th Step – Optimization 
• PFMEA 7th Step – Communication 
• Design FMEA and Process FMEA Linkages 
• Perform a Process FMEA prepared using the new AIAG & VDA FMEA Handbook 
• Evaluating PFMEA application cases 
• PFMEA effectiveness, efficiency, and linkage to the Cost of Poor Quality (COPQ) 
• Implementation Plan for the AIAG & VDA FMEA 
• Process FMEAs and Control Plan Linkages 
• Developing and Implementing Control Plans
• Control Plan Application